Method of Forming a Consolidated Fibrous Structure

ABSTRACT

A method of consolidating thermoplastic fibrous layers. The method begins with providing a plurality of fibers, where the fibers have a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core. The first layer contains a first polymer, where the first polymer contains at least 70% α-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core. These fibers are formed into a fibrous layer. Next, a second layer is applied to the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers. The second layer contains a second polymer being a co-polymer having at least 50% α-olefin units which is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface of the core. The viscosity of the second polymer is less than a tenth of the viscosity of the first polymer measured at 170° C. Next, heat and optionally pressure are applied to the fibrous layer causing at least a portion of the second layers of the fibers in each fibrous layer to fuse to other first or second layers of the fibers within the same fibrous layer, at least a portion of the second layers of the fibers of each fibrous layer fuse with at least a portion of the first or second layers of the fibers in an adjacent fibrous layer, and at least a portion of the interstices to be filled with a blend of the first and second polymers, where the blend filling the interstices comprises at least 80% wt the second polymer.

RELATED APPLICATIONS

This application is related to the following applications, each of which is incorporated by reference: Attorney docket number 6297, filed on Jan. 27, 2009 entitled, “Consolidated Fibrous Structure”; Attorney docket number 6298, filed on Jan. 27, 2009 entitled, “Consolidated Fibrous Structure”; Attorney docket number 6301, filed on Jan. 27, 2009 entitled, “Multi-Layered Fiber”; and Attorney docket number 6302, filed on Jan. 27, 2009 entitled, “Multi-Layered Fiber”.

TECHNICAL FIELD

The present application is directed to methods of forming consolidated fibrous layers and consolidated fibrous structures.

BACKGROUND

Consolidation of thermoplastic fibers into a fibrous structure such as the consolidation of polypropylene fibers for molded parts and other applications is typically accomplished by hot pressing under pressure at typically high temperatures (about 300° F. or more) and typically high pressures of (about 300 psi or more) to obtain consolidated fibrous structures having the desired performance attributes. The high temperature requirement hinders the ability to co-process the polypropylene fibers with other materials such as polymer fibers that are compromised at or above 250° F. The high pressure requirements prevent these materials from being processed in cost-effective autoclavable processes where the maximum application pressure is often about 45-100 psi. Due to the existing method of high temperature-high pressure consolidation, manufacturability of large parts requires large metal moulds which add to the cost of the machinery and finished parts significantly.

Thus, there is a need for a method that produces the same or better performance characteristics for thermoplastic fibrous layers and structures at lower temperatures, pressures, and/or dwell times than the prior art higher temperatures and pressures processes.

BRIEF SUMMARY

The present disclosure provides a method of producing consolidated fibrous structure and consolidated fibrous layers. According to one aspect, a method of consolidating thermoplastic fibrous layers is provided. The method begins with providing a plurality of fibers, where the fibers have a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core. The first layer contains a first polymer, where the first polymer contains at least 70% α-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core. These fibers are formed into a fibrous layer. Next, a second layer is applied to the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers. The second layer contains a second polymer being a co-polymer having at least 50% α-olefin units which is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface of the core. The viscosity of the second polymer is less than a tenth of the viscosity of the first polymer measured at 170° C. Next, heat and optionally pressure are applied to the fibrous layer causing at least a portion of the second layers of the fibers in each fibrous layer fuse to other first or second layers of the fibers within the same fibrous layer, at least a portion of the second layers of the fibers of each fibrous layer fuse with at least a portion of the first or second layers of the fibers in an adjacent fibrous layer, and at least a portion of the interstices to be filled with a blend of the first and second polymers, where the blend filling the interstices comprises at least 80% wt the second polymer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates schematically a cross-section of an exemplary consolidated fibrous structure.

FIG. 2 illustrates schematically a cross-section of an exemplary fiber of tape construction containing a core with a first layer on one side of the core and a second layer covering the first layer on the core.

FIG. 3 illustrates schematically a cross-section of an exemplary fiber of tape construction containing a core with two first layers sandwich the core and one second layer covering one of the first layers.

FIG. 4 illustrates schematically a cross-section of an exemplary fiber of tape construction having a first layers on both sides of the core and second layers on both of the first layers.

FIG. 5 illustrates schematically a cross-section of an exemplary fiber of tape construction having a first layers on both sides of the core and second layers on both of the first layers, where the core has an inner portion and an exterior surface portion of the core.

FIG. 6 illustrates schematically an exemplary fiber of circular cross-section having a first and second layer surrounding a core.

FIG. 7 illustrates schematically an exemplary fiber of oval cross-section having a first and second layer surrounding a core.

FIG. 8 illustrates schematically an exemplary fiber of circular cross-section having a first and second layer surrounding a core, where the core has an inner portion and an exterior surface portion of the core.

FIG. 9 illustrates schematically a cross-section of an exemplary fibrous layer having a woven construction.

FIG. 10 illustrates schematically a cross-section of an exemplary fibrous layer having a unidirectional construction.

FIG. 11 illustrates schematically a cross-section of an exemplary fibrous layer having a knit construction.

FIG. 12 illustrates schematically a cross-section of an exemplary fibrous layer having a non-woven construction.

FIG. 13 is a micrograph of a woven construction having a continuous first layer on the core and a discontinuous second layer on the first layer.

FIG. 14 is an illustration of the micrograph of FIG. 13.

FIG. 15 illustrates schematically a consolidated fibrous structure in a three-dimensional shape.

FIG. 16 illustrates schematically a cross-section of two fibrous layers consolidated together showing polymer at least partially filling the interstices of the fibrous layers.

FIG. 17 illustrates schematically a cross-section of an exemplary fibrous layer having a unidirectional construction where the fibers have continuous first and second layers on one side of a core and discontinuous first and second layers on the second side of the core.

FIG. 18 illustrates schematically a cross-section of a fibrous layer showing 2 fibers fused together.

FIG. 19 is a 100× image of a fibrous layer as illustrated in FIG. 18 illustrating the peeling failure mode.

FIG. 20 is an illustrative version of the image of FIG. 19.

FIG. 21 is a 200× image of fibers peeled apart having the interface between the second layer and the second layer fail.

FIG. 22 is an illustrative version of the image of FIG. 21.

DETAILED DESCRIPTION

Referring now to FIG. 1, there is shown one embodiment of the consolidated fibrous structure 200 which is formed from three (3) fibrous layers 100. Each fibrous layer 100 contains fibers 10 having a core 12 with an exterior surface portion comprising polypropylene, first layers 14 and 14′, and second layers 16 and 16′. The stiffness of the consolidated fibrous structure is at least about 1 N-m, more preferably at least 5 N-m measured by ASTM D 790.

FIGS. 2-8 illustrate different configurations of the fibers 10. For purposes of the present application, fiber is defined as an elongated body, the length at least 100× the square root of the cross-sectional area. Accordingly, the term fiber as used herein includes a monofilament elongated strand, a multifilament elongated body, ribbon, strip, tape, and the like. The term fibers include a plurality of any one or combination of the above. FIG. 2 shows a fiber 10 being a tape element having a core 12, a first layer 14 on one side of the core 12 and a second layer 16 on the first layer 14. FIG. 3 shows a fiber 10 being a tape element having a core 12 and two first layers 14 and 14′ sandwiching the core 12 and one second layers 16 on one of the first layers 14. FIG. 4 shows a fiber 10 being a tape element having a core 12 and two first layers 14 and 14′ sandwiching the core 12 and two second layers 16 and 16′ sandwiching the first layers. FIG. 4 illustrates an embodiment where the core has an inner portion 12″ and an exterior surface portion 12′ including polypropylene. The inner portion 12″ may be, but is not limited to, polypropylene, polyethylene, polyester, polyamides, polyethers, or copolymers thereof; glass fiber, aramid, carbon fiber, ceramic fiber, nylon, polyetherimide, polyamide-imide, polyphenylene sulfide, polysulfones, polyimide, conjugated polymers, mineral fiber, natural fibers, metallic fiber or mixtures thereof. In one embodiment, the inner portion 12″ of the core 12 has a tensile modulus of greater than 15 grams per denier as measured by ASTM method 3811-07. The inner portion 12″ and exterior surface portion 12′ of the core may be of the same or similar chemical composition or may be of different chemical composition with or without the use of surfactants, copolymers, or other means of reducing the surface energy difference between the inner core and exterior of the core. The interface between the inner portion 12″ and the exterior surface portion 12″ should have sufficient physical interlocking. In one embodiment, the fiber are high modulus fibers, being defined as fibers having a tensile modulus of greater than 10 grams per denier as measured by ASTM method 3811-07 and preferably have a tensile strength of at least 100 MPa.

FIG. 6 shows a fiber 10 being a fiber having a circular cross-section construction having a core 12, a first layer 14 surrounding the core 12, and a second layer 16 surrounding the first layer 14. FIG. 7 shows an embodiment of the fiber 10 being a fiber having an oval or oblong cross-section having a core 12, a first layer 14 surrounding the core, and a second layer 16 covering a portion of the first layer 14. The second layer 16 is discontinuous around the circumference of the core 12 and may be continuous or discontinuous down the length of the core 12. FIG. 8 illustrates an embodiment where the core has an inner portion 12″ and an exterior surface portion 12′ being polypropylene. The exterior surface portion 12′ of the core 12 may be continuous or discontinuous. The inner portion 12″ may be, but is not limited to, polypropylene, polyethylene, polyester, polyamides, polyethers, or copolymers thereof; glass fiber, aramid, carbon fiber, ceramic fiber, nylon, polyetherimide, polyamide-imide, polyphenylene sulfide, polysulfones, polyimide, conjugated polymers, mineral fiber, natural fibers, metallic fiber or mixtures thereof. In one embodiment, the inner portion 12″ of the core 12 has a tensile modulus of greater than 15 grams per denier as measured by ASTM method 3811-07. The inner portion 12″ and exterior surface portion 12′ of the core 12 may be of the same or similar chemical composition or may be of different chemical composition with or without the use of surfactants, copolymers, or other means of reducing the surface energy difference between the inner core and exterior of the core. The interface between the inner portion 12″ and the exterior surface portion 12′ should have sufficient physical interlocking as to prevent delamination between the inner portion 12″ and the exterior surface portion 12′ of the fiber 12 in the final product.

The core 12 of the fiber 10 has a high modulus (greater than 10 grams per denier) to provide stiffness for the fiber 10. It is contemplated that the core 12 of the fibers 10 is preferably made up of a molecularly-oriented thermoplastic polymer. The core 12 may account for about 50-99 wt. % of the fiber 10. Preferably, the core 12 of the fiber 10 has a tensile modulus of at least greater than 10 grams per denier as measured by ASTM method 3811-07, and more preferably greater than 40 grams per denier. According to one practice, the core 12 of the fiber 10 is polypropylene and is highly drawn with a draw ratio greater than 10:1. The core 12 (inner portion 12″ and exterior surface portion 12′) of fiber 10 has a peak melting temperature equal to or higher than the all the first layers 14, 14′ and the second layers 16, 16′. Preferably, the core 12 (inner portion 12″ and exterior surface portion 12′) of the fiber 10 has a peak melting temperature of at least 5° C. greater than the first layers 14, 14′ and the second layers 16, 16′, more preferably at least 10° C. greater than the first layers 14, 14′ and the second layers 16,16′.

In one embodiment, the fibers 10 are tape elements having a core 12 and at least one first layer 14, 14′ on at least a portion of the core 12 and at least one second layer on at least a portion of the first layer(s) 14, 14′. The tape fibers 10 may be formed by slitting a film. The film may be formed by any conventional means of extruding such multilayer polymeric films. By way of example, and not limitation, the film may be formed by blown film or cast film extrusion. The film is then cut into a multiplicity of longitudinal strips of a desired width by slitting the film to yield tape fibers 10 having cross-sections in the thickness dimension as shown in FIGS. 2-5. The tape fibers 10 are then preferably drawn in order to increase the orientation of the core 12 so as to provide increased strength and stiffness of the material. After the drawing process is complete, in one embodiment, the resulting strips are in the range of about 1 to about 5 millimeters wide.

Fiber elements being tape elements, core-shell elements, and their textile layer constructions are believed to be more fully described in U.S. Patent Publication No. 2007/0071960 (Eleazer et al.), U.S. patent application Ser. No. 11/519,134 (Eleazer et al.), and U.S. Pat. No. 7,300,691 (Eleazer et al.), U.S. Pat. No. 7,294,383 (Eleazer et al.), and U.S. Pat. No. 7,294,384 (Eleazer et al.), each of which is incorporated by reference.

The core 12 (or exterior surface portion 12′ of the core 12) is compatibly bonded to each of first layers 14, 14′ along their respective surfaces. The first layers 14, 14′ contain a first polymer. The first layers 14, 14′ may be continuous or discontinuous on the core 12. Preferably, the first layers 14, 14′ account for about 0.25 to 25 vol. % of the fiber 10. The second layers 16, 16′ contain a second polymer. Preferably, the second layers 16, 16′ account for about 0.5 to 45 vol. % of the fiber 10. The core 12, the first layer(s) 14, 14′, and the second layer(s) 16, 16′ may be co-extruded together, or the first and/or second layer(s) may be applied to the core 12 after the core 12 has been formed. Additionally, a portion of the first and second layer(s) may be applied during or after core formation with the balance of the first and second layer(s) being introduced at a later point. The fiber 10 may be drawn or oriented before or after the additional layer(s) are formed in order to increase the orientation of the core 12 so as to provide increased strength and stiffness or achieve a targeted core dimension.

The first polymer comprises a polymer having at least about 70% α-olefin units and is compatible with the polypropylene of the exterior surface portion 12′ of the core 12. Preferably, the first polymer is a co-polymer having at least about 70% α-olefin units. “Compatible”, in this application, is defined as two or more polymers that are inherently or enhanced to remain mixed without objectionable separation over the range of processing conditions that will form the final product. “α-olefin”, in this application, is defined as 1-alkene olefin monomer units other than ethylene such as propylene, butylene, 4-methyl-1-pentene, pentene, 1-octene, and the like. It may be preferred for the first polymer to have an ethylene content of about 1-25 mol. %, and a propylene content of about 75-99 mol. %. It may be further preferred for the first polymer to have a ratio of about 95 mol. % propylene to about 5 mol. % ethylene. In one embodiment, the first polymer is a terpolymer, one example being a terpolymer of ethylene, propylene, and butylene. The first polymer has a viscosity of greater than 150,000 cP measured at 170° C. and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The first polymer has at least ten times the viscosity of the second polymer, measured at 170° C. In one embodiment, the first polymer has a melting temperature of between about 120 and 140° C., a weight average molecular weight of between about 300,000 and 350,000, a viscosity of about 4,000,000 to 7,000,000 cP at 170° C., a melt flow index of between about 4 and 8 grams/10 minutes measured at 230° C., and a polydispersity of between about 3 and 6. “Melting temperature”, in this application, is defined to be the lower of the peak melting temperature or the temperature at which 50% of the polymer has melted from the solid state as measured by Differential Scanning Calorimetry (DSC). Preferably, the first polymer as a melting temperature of at least about 10° C. lower than that of the exterior surface portion 12′ of the core 12, and preferably between about 15-40° C. lower. In one embodiment, the tensile modulus of the first polymer is greater than about 100 MPa, preferably greater than about 500 MPa and most preferably greater than about 1 GPa.

The second layer(s) 16, 16′ contain a second polymer. The second polymer comprises a co-polymer having at least 50% α-olefin units. Preferably, the second polymer comprises a co-polymer having at least 50% propylene units, more preferably 80% propylene units, most preferably more than 82% propylene units. The second polymer comprises a number-average molecular weight of between about 7,000 g/mol and 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second polymer has a viscosity of not greater than about 10% the viscosity of the first polymer measured at 170° C. If the polymer has a number-average molecular weight lower than 7,000 g/mol or a viscosity lower than 2500 cP, the molecular chains of the second polymer are too short to entangle with one another and are too weak to effectively fuse with the first polymers. A polymer with a viscosity of greater than 150,000 cP has a reduced ability to flow into the interstices of the fiber layers and penetrate into the first polymer under lower temperature and pressure consolidation conditions. The melting temperature of the second polymer is preferably lower than the core in order to fuse the layers together without compromising the integrity of the core. In one embodiment, the second polymer has a weight average molecular weight of between about 20,000 and 40,000 g/mol, a number average molecular weight of between about 7,000 and 22,000.

In one embodiment, the viscosity of the second polymer is between about 4,000 and 120,000 cP measured at 170° C., more preferably between about 4,000 and 16,000 cP. In one embodiment, elongation at break is greater than about 200%, more preferably greater than about 400%. In one potentially preferred embodiment, the second polymer has a lower melting temperature than the first polymer. This aids in allowing the second polymer to flow into the interstices and penetrate into the first polymer. In one embodiment, the second polymer has a cohesion strength of at least about 1 MPa, more preferably greater than about 4 MPa. Having a cohesion strength in this range provides a polymer that resists tearing. In one embodiment, the viscosity of the second polymer is between about 0.005 to 10% the viscosity of the first polymer measured at 170° C., more preferably about 0.1 and 10%. The large difference in viscosity is believed to help facilitate the structural adhesion between the first polymer and the core and the filling of the interstices of the fibrous layers by the second polymer. Generally it has been found that an increase in the molecular weight leads to an increase in the cohesion strength and the viscosity of the polymer. The first polymer provides the strength of the reinforcement and is expected to have a high molecular weight and hence a higher cohesion strength and viscosity. The second polymer penetrates into the first polymer at least slightly and aids in processing. The second layer also fills the interstices of the fibrous layers to provide additional reinforcement. In one embodiment, the tensile modulus of the second polymer is greater than about 0.1 MPa, preferably greater than about 0.5 MPa and most preferably greater than 1 MPa. The percentage by weight of the second polymer to the total weight of the fiber is between about 0.25% wt and 50% wt, more preferably between about 1 % wt and 25% wt. In one preferred embodiment, the second polymer comprises a metallocene catalyzed propylene-ethylene co-polymer.

The fibers 10 are in fibrous layers 100. These fibrous layers 100 may contain fibers in woven, non-woven, knit, or unidirectional constructions (or mixtures of these constructions). Referring now to FIG. 8, there is shown fibers 10 in a woven construction. While the fibers shown in FIGS. 8 are tape fibers having a core 12, first layers 14 and 14′ and second layers 16 and 16′, other fiber types, shapes, and different arrangements of the first and second layers may be utilized. As illustrated, the fibrous layer 100 preferably includes a multiplicity of warp fibers 10 running in the warp direction interwoven with fill fibers 10 running in the fill direction in transverse relation to the warp fibers 10. As shown, the fill fibers are interwoven with the warp fibers such that a given fill extends in a predefined crossing pattern above and below the warp. In on embodiment, the fill fibers and the warp fibers are formed into a so called plain weave wherein each fill fiber passes over a warp fiber and thereafter passes under the adjacent warp fiber in a repeating manner across the full width of the fibrous layer 100. However, it is also contemplated that any number of other weave constructions as will be well known to those of skill in the art may likewise be utilized. By way of example only, and not limitation, it is contemplated that the fill fibers may pass over two or more adjacent warp fibers before transferring to a position below one or more adjacent warp fibers thereby forming a twill weave. The term “interwoven” is meant to include any construction incorporating interengaging formation fibers.

FIG. 9 illustrates a fibrous layer 100 having a unidirectional construction formed from a multiplicity of fibers 10 being tape elements. The fibers are aligned parallel along a common fiber direction of the fibrous layer 100. In one embodiment, the fibers 10 in the fibrous layer 100 do not overlap one another, and may have gaps between the fibers 10. In another embodiment, the fibers overlap one another up to 90% in the fibrous layer 100. One approach for aligning the fibers (especially tape elements) is to align the fibers into a sheet by pulling the fibers from a creel. Using a roll-off creel is helpful to reduce twist in the fibers. The common fiber direction of the fibers 10 in one fibrous layer 100 is the same (parallel to) as the common fiber direction of the fibers 10 of the adjacent fibrous layer. In the consolidated fibrous structure 200, the common fiber direction of the fiber 10 in one layer 100 may be parallel, perpendicular, or have any other rotational degree relative to the fiber direction in the adjacent fibrous layers 100.

FIG. 10 illustrates a fibrous layer 100 having a knit construction. The warp and weft fibers are circular cross-section fibers 10. There is also a stitching fiber 15 which may be the same as fiber 10 or may be another thermoplastic or non-thermoplastic fiber. The knit fibrous layer 100 may be any known knit, including, but not limited to circular knit, warp knit, weft-inserted warp knit, double needle bar, and jacquard knit fabrics.

FIG. 11 illustrates a fibrous layer 100 having a non-woven construction. The fibers 10 are tape fibers. The core 12, the first layers 14, 14′ and the second layers 16, 16′ are not shown for simplicity. The term “non-woven” refers to structures incorporating a mass of fiber elements that are entangled and/or heat fused so as to provide a coordinated structure with a degree of internal coherency. Non-woven fibrous layers or webs may be formed from many processes such as for example, meltspun processes, hydroentangling processes, mechanically entangled processes, needle punched processes, air-laying processes and wet laying processes, laid scrims and the like. In the fibrous layers, the fibers 10 may be unattached from one another or fused to one another. In the fused configuration, at least a portion of the second layer(s) 16, 16′ of the fibers 10 within the fibrous layer 100 are fused to either second layers 16, 16′ or other first layers 14′14 of other fibers 10.

The fibrous layer 100 is heated, preferably under pressure, to a temperature below the softening point of the core 12 and preferably higher than the melting point of the first layers 14, 14′ and the second layers 16, 16′. In so doing, the first and second layers will melt while the core 12 will remain substantially solid and highly oriented. As the fibrous layer 100 then cools, the first and second layers will fuse together, thereby forming a solid matrix. Fused or un-fused individual fibrous layers 100 may be stacked and reheated to form the consolidated fibrous structure 200.

At least 3 of the fibrous layers 100 are stacked together and consolidated using heat and/or pressure to form a consolidated fibrous structure 200 such as shown in FIG. 1. While the consolidated fibrous structure 200 has been depicted in FIG. 1 as including three (3) fibrous layers 100, those of ordinary skill in the art will readily appreciate that the consolidated fibrous structure 200 can comprise any suitable number of fibrous layers 100. In one embodiment, at least two (2) fibrous layers are consolidated together. In other embodiments, the consolidated fibrous structure 200 can comprise greater than three fibrous layers. By way of example only and not limitation, such structures may have ten fibrous layers, twelve fibrous layers, eighteen fibrous layers, twenty fibrous layers, thirty fibrous layers, or forty fibrous layers. While FIG. 1 shows each of the fibrous layers 100 containing the same type of fibers 10 and layer construction (woven in the case of FIG. 1), the consolidated fibrous structure 200 may contain many different fibrous layer 100 constructions and fibers 10 in the structure 200.

Several layers of fibrous layers 100 may be stacked in layered relation prior to the application of heat and pressure in order to form the consolidated fibrous structure 100. The layers of the fibrous layer 100 may be formed from a single sheet of a fibrous layer that is repeatedly folded over itself, or from several discrete overlaid fibrous layers. Alternatively, the structure 200 may be formed by reheating several previously fused fibrous layers 100. Any of these methods may be employed to form a structure 200 with any desired thickness or number of layers.

Consolidation of multiple fibrous layers 100 is preferably carried out at suitable temperature and pressure conditions to facilitate both interface bonding fusion and partial migration of the melted first and second layers material between the layers. It has been found that having a first polymer in a first layer and a second polymer in a second layer aids in the ability to use lower temperature, pressure, and/or dwell time consolidation conditions with the same or better properties as compared to a fiber having only the first polymer in one layer. Heated batch or platen presses may be used for multi-layer consolidation. In one exemplary practice, autoclaves or vacuum bags may be used to provide the pressure during consolidation. Continuous consolidation methods such as calendaring or use of a single or double belt laminator may likewise be employed. It is contemplated that any other suitable press may likewise be used to provide appropriate combinations of temperature, pressure, and residence time. According to a potentially preferred practice, heating is carried out at a temperature of about 195-325° F. and a pressure of about 15-400 psi. When exposed to such an elevated temperature and pressure, the first and second layers will melt while the core 12 will remain substantially solid. Upon cooling, the first and second layers will fuse thereby forming a matrix through which the stiff core 12 are distributed. “Fuse” is defined as being joined as if by melting together. At least a portion of the second layers of the fibers 10 in each fibrous layer 100 are fused to at least a portion of other second layers or first layers within the same fibrous layer 100 and at least a portion of the second layers of the fibers 10 of each fibrous layer 100 are fused with at least a portion of the first layers and/or second layers 14, 14′ of the fibers 10 in an adjacent fibrous layer 100.

According to a potentially preferred practice, cooling is carried out under pressure to a temperature lower than about 100° F. It is contemplated that maintaining pressure during the cooling step tends to inhibit shrinkage of the core and ensures no loss of consolidation. Without being limited to a specific theory, it is believed that higher pressures may facilitate polymer flow at lower temperatures. Thus, at the higher end of the pressure range, (greater than about 200 psi) the processing temperature may be about 80-140° C.

The consolidated fibrous structure 200 may thereafter be subjected to three-dimensional molding under heat and pressure at temperatures above the softening point of the first and second layers so as to yield complex shapes. The fibrous structures may also be consolidated and molded in a single step forming structure 200 simultaneous with the formation of a subtle or complex shape. An example of a plurality of fibrous layers 100 formed into a consolidated fibrous structure 200 having a three-dimensional shape is shown in FIG. 15.

In one embodiment, the fibrous layers 100 contain interstices 22, or voids, between the fibers as shown, for example, in FIG. 16. It has been found that the second polymer is more mobile during the fusing process and more easily migrates into the interstices 22 of the fibrous layer 100. In some embodiments, there are also interstices formed between fibers of adjacent fibrous layers. Preferably, when the interstices are at least partially filled with the first and second polymer, the filled interstices contain at least about 80% by weight the second polymer. At least partially filling the interstices 22 of the fibrous layers 100 creates better adhesion between the fibrous layers 100 and a better performing end product.

In some embodiments, during consolidation of the fibrous layers 100 or structures 200 or during application of the second layer(s) 16, 16′ to the first layers 14, 14′, a portion of the second polymer and first polymer intermix forming a blend of the first and second polymers.

Semicrystalline polymers like the polyolefins involved in this patent comprise oriented crystallites separated by amorphous chains. During the melt-welding of polyolefins, especially polypropylene, the amorphous chains migrate towards the interface to maximize the entropy. Due to the accumulations of short amorphous chains, the strength of the interface can be very weak. In one embodiment, the first polymer and second polymer can be found to co-crystallize with one another resulting in a polymer blend with higher crystallinity than either polymer alone. The complementary crystallization is believed to enhance the physical properties of the skin yielding an improved skin layer. This is achieved through the second polymer increasing the mobility of the first polymer chains and allowing a more extensive crystallization. The second polymer, being compatible with the first, is also able to incorporate into the crystal structure of the first without the introduction of significant additional defects.

While not being bound to any theory, it is believed that typically, if a mixture of two polymers is melted and cooled one would expect the crystallinity to be a simple average rule of mixtures. However, if a lower molecular weight species (preferably metallocene polyolefins) is present at the interface, the shorter molecular chains co-crystallize with the amorphous chains at the interface. In this case the final crystallinity of the polymer mixture is higher than either of the two polymers. In the preferred embodiment the crystallinity of the heated-cooled mixture of the first and second layers is higher than any of the two layers separately. This co-crystallization phenomenon imparts great strength to the interface between the first and second layers 14, 14′, 16, and 16′. The degree of co-crystallization is dependent on the molecular chain length of the amorphous segments of the first polymer and on the crystallizable chain length of the second polymer. Another phenomenon that could control the degree of co-crystallization is the rate of cooling. The rate of cooling is dependent on the consolidation conditions.

The first layers 14, 14 may be applied to the core 12 of the fibers 10 in any known method. The first layers may be co-extruded or otherwise formed at the same time as the core of the fibers or may be applied to a core after the core is formed. The first layers 14, 14′ may be applied to individual cores or onto cores that have already been formed into a fibrous layer. The first layers 14, 14′ may be continuous or discontinuous. FIG. 17 illustrates a fibrous layer 100 being a unidirectional layer having a continuous first layer 14 and second layer 16 on one side of core and a discontinuous first layer 14′ and second layer 16′ on the opposite side of the core. These discontinuous regions may be along a single fiber 10 or across multiple fibers 10. This application may be conducted by any known means including, but not limited to, solvent coating, curtain coating, extrusion coating, inkjet printing, gravure printing, solvent coating, powder coating, covering the core with a spunbond layer, or covering the core with a separate film layer comprising the first polymer.

The second layers 16, 16′ may be applied to at least a portion of the first layers 14, 14′ in any known method. Having the first and second layers as separate layers has the advantage that the methods, amounts, and patterns of the first and second layers may be controlled independently. The first layers may be co-extruded or otherwise formed at the same time as the core of the fibers or may be applied to the first layers after the cores and/or first layers are formed. It is speculated that a concentration gradient created by applying the layers independently may accelerate the “fusing” of the first and second polymer. If the second layer is applied separately onto the first layer it can melt, flow into the interstices and reinforce it. This will offer additional stiffness and interfacial strength to the composite structure. When the second polymer is applied as a second layer on at least a portion of the first layer, the first and second polymers can intermingle during the heating cycle of the consolidation process and hence result in overall viscosity reduction of the first layers. In one embodiment, the second layer is applied to individual fibers having a core and a first layer. In another embodiment, the second layer is applied onto fibrous layers containing fibers having a core and first layer. The following methods may be applied to fibers or fibrous layers.

According to one method, the second layers 16, 16′ are applied to at least a portion of the first layers 14, 14′ by a printing method. The second polymer may be applied as a polymer melt or in a solvent. The printing method may print a continuous layer or a discontinuous layer, the discontinuous layer being random or patterned. One preferred printing method is gravure printing. In the gravure coater the melted adhesive is taken up by the pattern on the gravure imprinter. When the roll of a fibrous layer is passed through a gravure imprinter, the graver physically transfers the second polymer onto a fibrous layer 100. The patterning of the second layer will depend on the pattern on the gravure roll. Other preferred printing methods include, but are not limited to inkjet printing, thermal printing, and silk screening. Printing is preferred as the amount and location of the second polymer being applied can be carefully controlled and allows the fibrous layer to maintain drape/moldability. FIG. 13 is a micrograph illustrating a woven fibrous layer comprising fibers being tape elements. The tape elements have a core surrounded by two first layers. The first layers are continuous on the core. The second layer was gravure printed on the surface of the fibrous layer in a dot pattern. An illustration of the micrograph is shown as FIG. 14.

According to another method, the second polymer may be solvent coated in a continuous or discontinuous method by solvent coating. Such coating methods include, but are not limited to roller coating, air knife coating, rod coating, electrostatic coating, slide hopper coating, extrusion coating, blade coating, curtain coating, and slide coating.

According to another method, the second polymer may be applied to the first layers as a powder. This method may be preferred for second polymers that do not easily dissolve or disperse in a solvent or melt extrude. The powder coating may be in a continuous layer or in a discontinuous layer. Powder coating may be more preferred in cases that require a higher add-on concentration of the second polymer and in cases where usage of a solvent may be disruptive. Powder coating may also be preferred when the consolidation is a continuous process as the powder coating may be added in-line.

According to another method, the second polymer may be applied as a freestanding layer such as a film, melt-blown layer, or scrim. To create a melt-blown layer, the second polymer is melted and used as the feed in a melt blowing machine. In the melt blowing operation, the polymer melt is delivered to the nozzles through a feed pump and is impinged by hot air at high pressures. Melt-blown application will apply low add-ons at high speed and create fine fibers for a uniform coating. Melt-blowing and spunbond layers are very uniform and also have the advantages of being solvent free and hence are more cost-effective.

One contemplated practice to form multi-layered fiber comprises providing an elongated core having an exterior surface portion comprising polypropylene and applying a first and second layer to at least a portion of the core. The first layer contains a first polymer which contains a polymer having at least 70% α-olefin units and is characterized by a viscosity of greater than 1,000,000 cP measured at 170° C. and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second layer contains a second polymer which is a propylene co-polymer having at least 80% propylene units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 4,000 and 10,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the first polymer. In this embodiment, the ratio by weight of the second polymer to the first polymer is between about 1:20 to 20:1.

How well the consolidated fibrous layer performs can be evaluated by testing stiffness and peel strength (both of which are described in detail in the examples section). During the peel test, the fiber-fiber unit fails either at the core-first layer interface or the second layer-second layer interface.

A section of the consolidated fibrous structure has two interfaces as shown in FIG. 18. The core-first layer adhesion is fixed by the method at which the first layer was applied to the core (for example, co-extruded or coated on). When the core has a first layer on at least a portion of the core and the first layer has a second layer on at least a portion of the first layer, the second layer-first or second layer interface is strong resulting in a failure between the core and the first layer or within the core itself. This can be seen in the 100× micrograph of FIG. 19. An illustration of the image is shown in FIG. 20. One is able to determine where in the structure the failure mode happened by the appearance, or lack thereof, of oriented fibers at the split. These oriented fibers are parts of the oriented core stripping away from the core.

If the second layer-first layer adhesion or second layer cohesion is not stronger than the core-first layer adhesion, the failure will occur between the second layer and another second layer or first layer resulting in a smooth split as can been seen in the 200× micrograph of FIG. 21 and as an illustration of the micrograph in FIG. 22. The first layer-second layer adhesion may be influenced by various parameters. One parameter for the selection of the layers is its chemical compatibility which influences its wetting behavior. In the preferred embodiment there is a very good compatibility and hence a very good wetting (indicated by a low contact angle) between the first polymer and the second polymer.

The fibrous layers 100 and consolidated fibrous structure 200 may contain additional fibers or layers. Examples of additional fibers that may be incorporated include, but are not limited to fibers made from highly oriented polymers, such as gel-spun ultrahigh molecular weight polyethylene fibers, melt-spun polyethylene fibers, melt-spun nylon fibers, melt-spun polyester fibers, sintered polyethylene fibers, rigid-rod polymers, carbon fibers, aramid fibers, glass fibers, polylactic acid fibers, and natural fibers such as cotton.

Additional films such as polycarbonate films, polyester films, polyethylene films, and polypropylene films may be included into the structure 200. In some embodiments, additional panels may be included with the structure 200 such as ballistics panels or the like.

The fibers, fibrous layers, and consolidated fibrous structures may be used for many purposes in many different applications that would be unavailable to fibers having a core and a first layer having only the first polymer. Having a first layer containing a first polymer and a second layer containing a second polymer allows for the same or better performance of the element or structure as fibers with only the first polymer, but processed at much lower temperatures, pressures, and/or dwell time conditions.

EXAMPLES

Various embodiments are shown by way of the Examples below, but the scope is not limited by the specific Examples provided herein.

Test Methods

Stiffness was measured by ASTM D 790. For the peel strength test, the areal density of the specimen is adjusted to 0.21 psf (Typically 10 layer consolidated stacks are used). The samples are cut to 2″ width strips. The peel specimens are prepared by leaving a 1″ wedge at one end in the center of the stack (between layers 5 and 6) to grip the ends using fixtures mounted on the cross-head of an Instron. A 180 degree peel test is conducted with a crosshead speed fixed at 12″/min. The initial gauge length is 1″. The peel start point is 1″ and the end point is 9″. The peel strength is calculated by measuring the average peel force divided by the sample width. Melting temperatures were measured by DSC using a scanning rate of 20° C./min.

Control Example 1

Woven fibrous layers were formed from tape fibers in a 2×2 twill weave with 11 ends/inch and 11 picks/inch. The tape fibers had a size of 1020 denier per fiber, a width of 2.2 mm, and a thickness of 65 μm. The tape fibers had a polypropylene core layer having a tensile modulus of about 19 GPa surrounded by two first layers. The first layers contained a propylene copolymer having Mw of 280,000 g/mol, vicat softening point of 107° C., a melting temperature of about 117° C., and viscosity of 5,700,000 cP at 170° C. The surface layers comprised about 15% by thickness of the total tape fiber. The fiber had a tensile strength of approximately 7 g/d and a tensile modulus of approximately 15 GPa.

Ten (10) fiber layers were cut to a foot square (12″×12″) and stacked. The layers were placed between two aluminum platens at various temperatures (T=300° F., 250° F.) and a pressure of 50 psi for 10 minutes of heating time. The sample was then subsequently cooled to 100° F. The cooling rate was approximately 20° F./minute.

Working Example 1

Woven tape fibrous layers were formed as described in Control Example 1. Licocene® 2602, a metallocene type of polypropylene-polyethylene co-polymer obtained from Clariant was used as received. Licocene® 2602 had a viscosity of 6000 cP measured at 170° C. and a melting temperature of 75° C. The tensile modulus of Licocene® 2602 is measured to be approximately 0.7 MPa; has an elongation at break of 760% and cohesion strength of 9 MPa. The crystallinity of the polymer is ˜17%. A 2% by weight concentration of Licocene® 2602 in toluene was prepared by heating the appropriate amount of Licocene® 2602 pellets in toluene at 80° C. for 10 minutes. After obtaining complete dissolution of the polymer, the solution was cooled to room temperature with continuous stirring.

The Licocene®/toluene solution was then sprayed uniformly onto 12″×12″ woven tape fibrous layers with a 2 wt % dry add on. The layers were then dried overnight at room temperature. After drying ten woven tape fibrous layers were stacked and consolidated by being placed between heated aluminum platens at various temperatures (T=300° F., 250° F.) and a pressure of 50 psi for 10 minutes of heating time. The sample was then subsequently cooled to 100° F. The cooling rate was approximately 20° F./minute.

Working Example 2

Woven tape fibrous layers were formed as described in Control Example 1. Licocene® 2602, a metallocene type of polypropylene-polyethylene co-polymer obtained in powder form from Clariant and was used as received (Licocene® 2602 properties are described in Working Example 1). The Licocene® 2602 was sieved to obtain all particle sizes below 250 μm. The Licocene® powder was then applied uniformly with a 2 wt % add-on onto ten 12″×12″ woven tape layers. The woven tape layers they were stacked and consolidated by being placed between heated aluminum platens at various temperatures (T=300° F., 250° F.) and a pressure of 50 psi for 10 minutes of heating time. The sample was then subsequently cooled to 100° F. The cooling rate was approximately 20° F./minute.

Working Example 3

Woven tape fibrous layers were formed as described in Control Example 1. Licocene® 2602, a metallocene type of polypropylene-polyethylene co-polymer obtained from Clariant was used as received. (Licocene® 2602 properties are described in Working Example 1). Approximately 3 pounds of Licocene® pellets were melted in an oven at 230° C. for 1 hour. The melt was then used as the feed in a melt blowing machine. The temperature of the melt feeder was maintained at 230° C. In the melt blowing operation, the polymer melt was delivered to the nozzles through a feed pump and was impinged by hot air at high pressures.

The molten Licocene® polymer was deposited onto ten woven tape fibrous layers in the form of a spun-bond. The add on of Licocene® was 2% wt of the tape fiber. The coated woven tape layers were stacked and consolidated at various temperatures (T=300° F., 250° F.) and a pressure of 50 psi for 10 minutes of heating time. The sample was then subsequently cooled to 100° F. The cooling rate was approximately 20° F./minute.

Working Example 4

Woven tape fibrous layers were formed as described in Control Example 1. Licocene® 2602, a metallocene type of polypropylene-polyethylene co-polymer obtained from Clariant was used as received (Licocene® 2602 properties are described in Working Example 1). Approximately 2 pounds of Licocene® was input into the adhesive bath of a gravure coater and melted at a temperature of 297° F. In the gravure coater the melted Licocene is taken up by the pattern on the gravure imprinter, the pattern being a dot pattern having a density of 66 dots/cm², each dot having a depth of 0.25 mm. When the fibrous layer to be printed is passed through a gravure imprinter, the graver physically transfers the Licocene onto the material.

Ten woven tape layers were gravure coated with the Licocene® at a temperature of 297° F. After the woven tape layers were contacted by the gravure roll, they passed through a chill roll where the Licocene was cooled. The add on weight of the Licocene onto the fibrous layer was 2.1 % wt.

The printed woven tape layers were stacked and consolidated at various temperatures (T=300° F., 250° F.) and a pressure of 50 psi for 10 minutes of heating time. The sample was then subsequently cooled to 100° F. The cooling rate was approximately 20° F./minute.

Working Example 5

Woven tape fibrous layers were formed as described in Control Example 1. Licocene® 2602, a metallocene type of polypropylene-polyethylene co-polymer obtained from Clariant was used as received (Licocene® 2602 properties are described in Working Example 1). Approximately 0.5 pounds of Licocene® pellets were melted on a hot plate at 250° C. for 1 hour. Films of Licocene® 2602 were made using a 75 μm die. The Licocene® films were placed on ten woven tape layer and consolidated individually at 300° F. and 300 psi. The add on of Licocene® was 15 % wt of the tape fiber. The coated woven tape fibrous layers were stacked and consolidated at various temperatures (T=300° F., 250° F.) and a pressure of 50 psi for 10 minutes of heating time. The sample was then subsequently cooled to 100° F. The cooling rate was approximately 20° F./minute.

Results

TABLE 1 Peel Strength of Examples Peel Strength when Peel Strength when consolidated at a temp of consolidated at a 300° F. and a temp of 250° F. Example pressure of 50 psi and a pressure of 50 psi Control Ex. 1 3.4 lb_(f)/in 1.8 lb_(f)/in Working Ex. 1 8.6 lb_(f)/in 6.0 lb_(f)/in Working Ex. 2 7.5 lb_(f)/in 6.0 lb_(f)/in Working Ex. 3 8.0 lb_(f)/in 6.5 lb_(f)/in Working Ex. 4. 7.5 lb_(f)/in 6.0 lb_(f)/in Working Ex. 5 11.0 lb_(f)/in  8.0 lb_(f)/in

A peel strength of “No consolidation” indicates that fibrous layers did not hold together well enough to perform the peel strength test.

It can be seen from Table 1 that the peel strengths obtained by using the working examples are higher than the control samples at almost all temperatures. Working Example 1 had a peel strength 152% greater than Control Example 1 where both examples were processed at 300° F. and 50 psi. Working Example 1 had a peel strength 230% greater than Control Example 1 where both examples were processed at 250° F. and 50 psi. Further, Working Example 1 had a 76% greater peel strength processed at lower conditions (250° F., 50 psi) than Control Example 1 processed at much higher conditions (300° F., 50 psi). Working Examples 1-5 each had better performance at 250° F./50 psi than the control examples processed at 300° F./50 psi. Additionally, stiffness was measured for all samples and the Working Examples were at least as stiff as or stiffer than the Control Examples processed at the same conditions.

Having a first layer containing a first polymer and a second layer containing a second polymer enables the working examples to be consolidated at much lower temperatures, pressures and/or dwell time saving time and energy over prior art materials. 

1. A method of consolidation of thermoplastic fibrous layers comprising: a) providing a plurality of fibers, the fibers comprising: a core having an exterior surface comprising polypropylene; and, a first layer disposed on at least a portion of the core comprising a first polymer, wherein the first polymer comprises a polymer having at least 70% α-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core; b) forming the fibers into a fibrous layer selected from the group consisting of woven, non-woven, unidirectional, and knit, wherein the fibrous layers contain interstices between the fibers within each fibrous layer; c) applying a second layer to at least a portion of the surface of the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers, the second layer comprising a second polymer, wherein the second polymer comprises a co-polymer having at least 50% α-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., wherein the viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface of the core; and, d) applying heat and optionally pressure to the fibrous layer causing: at least a portion of the second layers of the fibers in each fibrous layer to fuse to other first or second layers of the fibers within the same fibrous layer, at least a portion of the second layers of the fibers of each fibrous layer fuse with at least a portion of the first or second layers of the fibers in an adjacent fibrous layer, and at least a portion of the interstices to be filled with the first and second polymers, wherein the filled interstices comprise at least 80% wt the second polymer.
 2. The method of claim 1, wherein the fibers comprise tape fibers.
 3. The method of claim 1, wherein the fibers are high modulus fibers defined as having a tensile modulus of greater than 10 grams per denier.
 4. The method of claim 1, wherein at least three (3) fibrous layers are stacked before applying heat and optionally pressure of step d).
 5. The method of claim 1, wherein at least ten (10) fibrous layers are stacked before applying heat and optionally pressure of step d).
 6. The method of claim 1, wherein the second polymer has a propylene content of greater than 80% by mole.
 7. The method of claim 1, wherein the first layer is discontinuous on the core.
 8. The method of claim 1, wherein the second layer is discontinuous on the first layer.
 9. The method of claim 1, wherein the melting temperature of the second polymer is lower than the melting temperature of the first polymer.
 10. A method of consolidation of thermoplastic fibrous layers comprising: a) providing a plurality of fibers, the fibers comprising: a core having an exterior surface comprising polypropylene; and, a first layer disposed on at least a portion of the core comprising a first polymer, wherein the first polymer comprises a polymer having at least 70% α-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core; d) applying a second layer to at least a portion of the surface of the fiber such that the second layer covers at least a portion of the first layers of the fibers, the second layer comprising a second polymer, wherein the second polymer comprises a co-polymer having at least 50% α-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., wherein the viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface of the core; and, c) forming the fibers into a fibrous layer selected from the group consisting of woven, non-woven, unidirectional, and knit, wherein the fibrous layers contain interstices between the fibers within each fibrous layer; d) applying heat and optionally pressure to the fibrous layer causing: at least a portion of the second layers of the fibers in each fibrous layer to fuse to other first or second layers of the fibers within the same fibrous layer, at least a portion of the second layers of the fibers of each fibrous layer fuse with at least a portion of the first or second layers of the fibers in an adjacent fibrous layer, and at least a portion of the interstices to be filled with the first and second polymers, wherein the filled interstices comprise at least 80% wt the second polymer.
 11. The method of claim 10, wherein the fibers comprise tape fibers.
 12. The method of claim 10, wherein the fibers are high modulus fibers defined as having a tensile modulus of greater than 10 grams per denier.
 13. The method of claim 10, wherein at least three (3) fibrous layers are stacked before applying heat and optionally pressure of step d).
 14. The method of claim 10, wherein at least ten (10) fibrous layers are stacked before applying heat and optionally pressure of step d).
 15. The method of claim 10, wherein the second polymer has a propylene content of greater than 80% by mole.
 16. The method of claim 10, wherein the first layer is discontinuous on the core.
 17. The method of claim 10, wherein the second layer is discontinuous on the first layer.
 18. The method of claim 10, wherein the melting temperature of the second polymer is lower than the melting temperature of the first polymer. 